Tri-fold plastic bag roll

ABSTRACT

A plastic bag is formed from a continuous extruded tube of polyethylene material. The tube is flattened and sealed across its width a intervals to form bag bottoms. The bags are joined to one another at a perforation line and folded in thirds lengthwise prior to being rolled into a compact roll, either with or without supporting core. After folding the bags may be chisel cut through the center of the perforation line to assist in dispensing of the bags. The chisel cut will extend through all layers of the bag when folded, resulting in three chisel cuts in the bag. The bags may be gusseted for part or as much as all of their width. The bags may also be corona treated and printed on their outer surfaces. The bags may be formed from partially recycled materials and various combinations of linear low density, medium and high density polyethylene.

RELATED APPLICATION

The instant application is a Divisional application of U.S. patentapplication Ser. No. 10/847,690, filed May 18, 2004 and currentlypending.

FIELD OF INVENTION

The invention pertains to plastic bags. More particularly, the inventionrelates to plastic bags designed for fresh produce that are dispensedfrom compact rolls and designed to be easily opened.

BACKGROUND OF THE INVENTION

Plastic bags have found wide use in grocery markets and retailapplications for transporting produce groceries and various other items.To be most useful for consumers plastic bags should incorporate a numberof features. These features relate to the ease of use of the bags withrespect to opening them, placing goods inside, carrying them anddispensing them.

A variety of designs have been developed. U.S. Pat. No. 6,196,717,issued to Belias et al., is directed to a A method of forming aplurality of easy to open handle bags including the steps of providing aflattened tube of thermoplastic material oriented in a generallylongitudinal direction. The flattened tube has a first longitudinal sideedge and a second longitudinal side edge, a transverse lower heat seal,and a transverse upper heat seal. The tube also has first, second, andthird sections. The second section is disposed between the first andthird sections. The first section is joined to the second section alonga generally longitudinal first fold line. The second section is joinedto the third section along a generally longitudinal second fold line.The second section is cut along a generally transverse first cut lineextending between the first and second fold lines. The first section isfolded over the second section along the first fold line. The thirdsection is folded over the previously folded-over first section alongthe second fold line such that the first, second, and third sectionsoverlap one another.

The overlapped first, second, and third sections are cut along agenerally longitudinal second cut line that intersects the first cutline, the first fold line, and the second side edge at one end andintersects the upper heat seal at the other end. The overlapped first,second, and third sections are then cut along a generally longitudinalthird cut line that intersects the first cut line, the second fold line,and the first side edge at one end and intersects the upper heat seal atthe other end.

U.S. Pat. No. 5,890,810, issued to Barlow, discloses an extrudedplastics tube that is flattened with the lateral side portions folded toform inwardly extending gussets. Each gusseted side portion is thenfolded about a longitudinal fold line onto the medial portion betweenthe side portions. The resultant layers are heat sealed to form thebottom of the bag.

U.S. Pat. No. 6,488,222, issued to West et al., describes A foldedgusseted plastic bag has a first side gusset formed by first, second,and third longitudinal folds, a second side gusset formed by fourth,fifth, and sixth longitudinal folds, a seventh longitudinal fold beingon a side of the bag containing the first, second, and third folds andforming a first folded bag flap, and an eighth longitudinal fold whichis on a side of the bag containing the fourth, fifth, and sixth folds,the eighth fold forming a second folded bag flap. The folded gussetedbag also is folded into a total of at least eight contiguous plies. Aroll of the folded, gusseted bags includes a continuous web of thefolded, flattened bags joined along perforated severance lines.Preferably the perforated severance lines further comprise acentrally-located slit. The dispensing system utilizes the roll offolded-gusseted bags in combination with a dispenser comprising: (i) asupport member for attachment to a support surface; (ii) a pair of guidechannels carried by the support member for rotatably supporting the rollof plastic bags for rotation of the roll on the core; (iii) a tonguespaced apart from and carried by said support member in a predeterminedposition corresponding to the predetermined position of the slit in thetear line.

U.S. Pat. No. 6,379,292, issued to Simhaee, illustrates a continuous webof bags formed of a plurality of layers to be separated along a line ofperforations that extends through all of the layers transverse of theweb, in which at least one of the outermost layers is detached from theweb at the separation line. Apparatus accomplishes this detachment in amoving web by engaging the outermost layer outer surface and exerting aforce in a manner to produce the detachment from the separation line.Both the outermost upper and lower web layers can be detached at theseparation line.

U.S. Pat. No. 5,967,663, issued to Vaquero et al., discloses athermoplastic bag structure and method for making and packagingthermoplastic bags such that their tops are easily identified and thebags are easily opened. The method for producing these bags begins withcutting a flattened thermoplastic tube into two portions. At least oneof the two portions is then collapsed to form a sheet of material havinga pair of thermoplastic layers, a straight folded bottom edge and a pairof top edges, at least one of which has a skewed-cut. Bag sidestructures are formed in the sheet of material at about bag-widthdistances apart. The bags are then folded a predetermined number oftimes, in a direction transverse to the bag side structures, so that theskewed-cut top edge(s) of each of the bags remains exposed.

It is an objective of the present invention to provide plastic bags thatcan be easily stored on and dispensed from a variety of types of compactroll dispensers. It is a further objective to provide bags that can beformed into compact rolls on cores or without cores. It is a stillfurther objective of the invention to provide bags that can be easilymanufactured in gusseted or ungusseted form. Finally, it is an objectiveto provide roll mounted bags that are easily opened after dispensing andthat are easily removed from the roll.

While some of the objectives of the present invention are disclosed inthe prior art, none of the inventions found include all of therequirements identified.

SUMMARY OF THE INVENTION

The present invention addresses all of the deficiencies of prior artfolded plastic bag inventions and satisfies all of the objectivesdescribed above.

(1) A tri-fold plastic bag providing the desired features may beconstructed from the following components. A continuous web of plasticbags formed from polyethylene material is provided. Each of the bagsincludes a front wall. The front wall has an inner surface, an outersurface, first and second side edges, a top edge and a bottom edge. Arear wall is provided. The rear wall has an inner surface, an outersurface, first and second side edges, a top edge and a bottom edge. Thefront wall is joined to the rear wall at respective first and secondside edges thereof. The front wall is sealed to the rear wall adjacentrespective bottom edges thereof. An open mouth is located at the topedges of the bag.

The front and rear walls of each of the bags are removably attached by aperforation line at the bottom edges to the top edges of a subsequentbag in the web. The web is folded twice parallel to a long axis of thebags to form a compact bag web approximately one third of a width of thebags. The folded web is rolled to form a compact bag roll.

(2) In a variant of the invention, a chisel cut is provided. The chiselcut extends through a center point of the perforation line of the foldedweb. When the compact roll is installed in a bag dispenser the chiselcut will engage a separating tongue when bags are pulled from the roll.When the bags are opened to their full width, three chisel cuts willappear at the perforation line.

(3) In a further variant, the compact web is rolled about a core.

(4) In still a further variant, the bags includes at least one sidegusset, the side gusset extending inwardly from either of the first andsecond side edges of the front and rear walls.

(5) In yet a further variant, the side gusset extends inwardly fromeither of the first and second side edges of the front and rear wallsfor up to one third of the width of the bags.

(6) In another variant of the invention, the side gusset extendsinwardly from either of the first and second side edges of the front andrear walls for up to one half of the width of the bags.

(7) In still another variant, the outer surface of at least one of thefront wall and the rear wall of the bags is corona treated.

(8) In a further variant, the corona treatment of the outer surface ofat least one of the front and rear walls of each of the bags is anamount sufficient to result in a surface tension on the wall of at leastabout 38 dynes/cm.

(9) In still a further variant, the outer surface of at least one of thefront wall and the rear wall of the bags is printed.

(10) In yet a further variant, the first side edges are folded over thesecond side edges.

(11) In another variant of the invention, the first side edges arefolded under the second side edges.

(12) In still another variant, the polyethylene material is formulatedfrom about 40-48 wt. % high density, high molecular weight polyethylene,12-20 wt. % high density, medium molecular weight polyethylene, 20-30wt. % linear low density polyethylene, 0-8 wt. % color concentrate.

(13) In a further variant, the polyethylene material is formulated fromabout 10-20 wt. % recycled material, the recycled material includesabout 40-48 wt. % high density, high molecular weight polyethylene,12-20 wt. % high density, medium molecular weight polyethylene, 20-30wt. % linear low density polyethylene and 0-8 wt. % color concentrate.

(14) In still a further variant, 10-15 wt. % of the linear low densitypolyethylene has a density ranging from 0.923-0.924 gm/cc.

(15) In yet a further variant, 10-15 wt. % of the linear low densitypolyethylene has a melt index ranging from 0.25-0.30 gm/10 minutes.

(16) In another variant of the invention, the high density, mediummolecular weight polyethylene has a density ranging from 0.937-0.947gm/cc.

(17) In a final variant, the high density, medium molecular weightpolyethylene has a melt index ranging from 0.10-0.30 gm/10 minutes.

An appreciation of the other aims and objectives of the presentinvention and an understanding of it may be achieved by referring to theaccompanying drawings and the detailed description of a preferredembodiment.

DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of the preferred embodiment of thetri-fold plastic bag roll, illustrating a compact bag roll without core;

FIG. 1B is a perspective view of the bag of the FIG. 1A embodiment;

FIG. 2A is a perspective view of the preferred embodiment of thetri-fold plastic bag roll, illustrating a compact bag roll with core;

FIG. 2B is a perspective view of the bag of the FIG. 2A embodiment;

FIG. 3A is a perspective view of an alternative bag of the FIG. 1Aembodiment, illustrating gussets approximately one third of the width ofthe bag;

FIG. 3B is a side elevational view of the FIG. 3A embodiment,illustrating the first side edges folded over the second side edges;

FIG. 4A is a perspective view of an alternative bag of the FIG. 1Aembodiment, illustrating gussets approximately one half of the width ofthe bag;

FIG. 4B is a side elevational view of the FIG. 3A embodiment,illustrating the first side edges folded under the second side edges;

FIG. 5 is a perspective view of the bag of the FIG. 1A embodimentillustrating printing on the outer surface of the bag;

FIG. 6 is a side elevational view of the FIG. 5 embodiment, illustratingthe first side edges folded over the second side edges; and

FIG. 7 is a side elevational view of the FIG. 5 embodiment, illustratingthe first side edges folded under the second side edges;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(1) FIGS. 1A, 1B, 2A and 2B illustrate a tri-fold plastic bag roll 10providing the desired features that may be constructed from thefollowing components. A continuous web 15 of plastic bags 20 formed frompolyethylene material 22 is provided. Each of the bags 20 includes afront wall 25. The front wall 25 has an inner surface (not shown), anouter surface 35, first 40 and second 45 side edges, a top edge 50 and abottom edge 55. A rear wall 60 is provided. The rear wall 60 has aninner surface (not shown), an outer surface 70, first 75 and second 80side edges, a top edge 85 and a bottom edge 90. The front wall 25 isjoined to the rear wall 60 at respective first 40, 75 and second 45, 80side edges thereof. The front wall 25 is sealed to the rear wall 60adjacent respective bottom edges 55, 90 thereof. An open mouth 95 islocated at the top edges 50, 85 of the bag 20.

The front 25 and rear 60 walls of each of the bags 20 are removablyattached by a perforation line 100 at the bottom edges 55, 90 to the topedges 50, 85 of a subsequent bag 20 in the web 15. The web 15 is foldedtwice parallel to a long axis 105 of the bags 20 to form a compact bagweb 110 approximately one third of a width 115 of the bags 20. Thefolded web 110 is rolled to form a compact bag roll 120.

(2) In a variant of the invention, as illustrated in FIGS. 2A and 2B, achisel cut 125 is provided. The chisel cut 125 extends through a centerpoint 130 of the perforation line 100 of the folded web 110. When thecompact roll 120 is installed in a bag dispenser (not shown) the chiselcut 125 will engage a separating tongue (not shown) when bags 20 arepulled from the roll 120. When the bags 20 are opened to their fullwidth 115, three chisel cuts 125 will appear at the perforation line100.

(3) In a further variant, as illustrated in FIG. 2A the compact web 15is rolled about a core 135.

(4) In still a further variant, as illustrated in FIGS. 3A, 3B, 4A and4B, the bags 20 includes at least one side gusset 145, the side gusset145 extending inwardly from either of the first 40, 75 and second 45, 80side edges of the front 25 and rear 60 walls.

(5) In yet a further variant, as illustrated in FIGS. 3A and 3B, theside gusset 145 extends inwardly from either of the first 40, 75 andsecond 45, 80 side edges of the front 25 and rear 60 walls for up to onethird of the width 115 of the bags 20.

(6) In another variant of the invention, as illustrated in FIGS. 4A and4B, the side gusset 145 extends inwardly from either of the first 40, 75and second 45, 80 side edges of the front 25 and rear 60 walls for to upone half of the width 115 of the bags 20.

(7) In still another variant, the outer surface 35, 70 of at least oneof the front wall 25 and the rear wall 60 of the bags 20 is coronatreated.

(8) In a further variant, the corona treatment of the outer surface 35,70 of at least one of the front 25 and rear 60 walls of each of the bags20 is an amount sufficient to result in a surface tension on the wall25, 60 of at least about 38 dynes/cm.

(9) In still a further variant, as illustrated in FIG. 5, the outersurface 35, 70 of at least one of the front wall 25, and the rear wall60 of the bags 20 is printed.

(10) In yet a further variant, as illustrated in FIG. 6, the first sideedges 40, 75 are folded over the second side edges 45, 80.

(11) In another variant of the invention, as illustrated in FIG. 7, thefirst side edges 40, 75 are folded under the second side edges 45, 80.

(12) In still another variant, the polyethylene material 22 isformulated from about 40-48 wt. % high density, high molecular weightpolyethylene, 12-20 wt. % high density, medium molecular weightpolyethylene, 20-30 wt. % linear low density polyethylene, 0-8 wt. %color concentrate.

(13) In a further variant, the polyethylene material 22 is formulatedfrom about 10-20 wt. % recycled material, the recycled material includesabout 40-48 wt. % high density, high molecular weight polyethylene,12-20 wt. % high density, medium molecular weight polyethylene, 20-30wt. % linear low density polyethylene and 0-8 wt. % color concentrate.

(14) In still a further variant, 10-15 wt. % of the linear low densitypolyethylene has a density ranging from 0.923-0.924 gm/cc.

(15) In yet a further variant, 10-15 wt. % of the linear low densitypolyethylene has a melt index ranging from 0.25-0.30 gm/10 minutes.

(16) In another variant of the invention, the high density, mediummolecular weight polyethylene has a density ranging from 0.937-0.947gm/cc.

(17) In still another variant, the high density, medium molecular weightpolyethylene has a melt index ranging from 0.10-0.30 gm/10 minutes.

The tri-fold plastic bag roll 10 has been described with reference toparticular embodiments. Other modifications and enhancements can be madewithout departing from the spirit and scope of the claims that follow.

1. A tri-fold plastic bag roll, comprising: a continuous web of plasticbags formed from polyethylene material, each of said bags comprising: afront wall, said front wall having an inner surface, an outer surface,first and second side edges, a top edge and a bottom edge; a rear wall,said rear wall having an inner surface, an outer surface, first andsecond side edges, a top edge and a bottom edge; said front wall beingjoined to said rear wall at respective first and second side edgesthereof; said front wall being sealed to said rear wall adjacentrespective bottom edges thereof; an open mouth disposed at said topedges; said front and rear walls of each of said bags being removablyattached by a perforation line at said bottom edges to said top edges ofa subsequent, bag in said web; said web being folded twice parallel to along axis of said bags to form a compact bag web approximately one thirdof a width of said bags; and said folded web being rolled to form acompact bag roll.
 2. The tri-fold plastic bag roll, as described inclaim 1, further comprising: a chisel cut, said chisel cut extendingthrough a center point of said perforation line of said folded web; andwhereby, when said compact roll is installed in a bag dispenser saidchisel cut will engage a separating tongue when bags are pulled fromsaid roll, and when said bags are opened to said width, three chiselcuts will appear at said perforation line.
 3. The tri-fold plastic bagroll, as described in claim 1, wherein said compact web is rolled abouta core.
 4. The tri-fold plastic bag roll, as described in claim 1,further comprising at least one side gusset, said side gusset extendinginwardly from either of said first and second side edges of said frontand rear walls.
 5. The tri-fold plastic bag roll, as described in claim4, wherein said side gusset extends inwardly from either of said firstand second side edges of said front and rear walls for up to one thirdof said width of said bags.
 6. The tri-fold plastic bag roll, asdescribed in claim 4, wherein said side gusset extends inwardly fromeither of said first and second side edges of said front and rear wallsfor up to one half of said width of said bags.
 7. The tri-fold plasticbag roll, as described in claim 1, wherein said outer surface of atleast one of said front wall and said rear wall of said bags is coronatreated.
 8. The tri-fold plastic bag roll, as described in claim 7,wherein said corona treatment of said outer surface of at least one ofsaid front and rear walls of each of said bags is an amount sufficientto result in a surface tension on said wall of at least about 38dynes/cm.
 9. The tri-fold plastic bag roll, as described in claim 7,wherein said outer surface of at least one of said front wall and saidrear wall of said bags is printed.
 10. The tri-fold plastic bag roll, asdescribed in claim 1, wherein said first side edges are folded over saidsecond side edges.
 11. The tri-fold plastic bag roll, as described inclaim 1, wherein said first side edges are folded under said second sideedges.
 12. The tri-fold plastic bag roll, as described in claim 1,wherein said polyethylene material is formulated from about 40-48 wt. %high density, high molecular weight polyethylene, 12-20 wt. % highdensity, medium molecular weight polyethylene, 20-30 wt. % linear lowdensity polyethylene, 0-8 wt. % color concentrate.
 13. The tri-foldplastic bag roll, as described in claim 1, wherein said polyethylenematerial is formulated from about 10-20 wt. % recycled material, therecycled material comprising about 40-48 wt. % high density, highmolecular weight polyethylene, 12-20 wt. % high density, mediummolecular weight polyethylene, 20-30 wt. % linear low densitypolyethylene, 0-8 wt. % color concentrate.
 14. The tri-fold plastic bagroll, as described in claim 12, wherein 10-15 wt. % of said linear lowdensity polyethylene has a density ranging from 0.923-0.924 gm/cc. 15.The tri-fold plastic bag roll, as described in claim 12, wherein 10-15wt. % of said linear low density polyethylene has a melt index rangingfrom 0.25-0.30 gm/10 minutes.
 16. The tri-fold plastic bag roll, asdescribed in claim 12, wherein said high density, medium molecularweight polyethylene has a density ranging from 0.937-0.947 gm/cc. 17.The tri-fold plastic bag roll, as described in claim 12, wherein saidhigh density, medium molecular weight polyethylene has a melt indexranging from 0.10-0.30 gm/10 minutes.